CA2440458C - Micro component hydrocarbon steam reformer system and cycle for producing hydrogen gas - Google Patents

Micro component hydrocarbon steam reformer system and cycle for producing hydrogen gas Download PDF

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CA2440458C
CA2440458C CA002440458A CA2440458A CA2440458C CA 2440458 C CA2440458 C CA 2440458C CA 002440458 A CA002440458 A CA 002440458A CA 2440458 A CA2440458 A CA 2440458A CA 2440458 C CA2440458 C CA 2440458C
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gas
module
fluid flow
steam reformer
channels
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CA2440458A1 (en
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James P. Seaba
Christopher J. Brooks
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Honda Motor Co Ltd
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    • C01B3/0005Reversible uptake of hydrogen by an appropriate medium, i.e. based on physical or chemical sorption phenomena or on reversible chemical reactions, e.g. for hydrogen storage purposes ; Reversible gettering of hydrogen; Reversible uptake of hydrogen by electrodes
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Abstract

A micro component steam reformer system for producing hydrogen-enriched gas to power a fuel cell (68) adapted for scalable power requirements. The steam reformer system uses a cycle in which, in laminar flow modules, a vaporized hydrocarbon is mixed with fuel cell off-gas having a hydrogen component and combusted to heat vaporizers (14, 18 and 22) and a steam reformer (34).
Vaporized hydrocarbons and water vapour are introduced as a feedstock into the steam reformer (34) to produce a syn-gas, which is cooled in heat exchangers (38, 46 and 54) and purified a shift reactors (42 and 50) and in preferential oxidation reactor (60). The resulting hydrogen gas may be introduced into a hydrogen fuel cell (68). Off-gas from the fuel cell (68) is recycled to provide hydrogen and water for use in the system cycle.

Description

TITLE OF INVENTION

Micro Component Hydrocarbon Steam Reformer System and Cycle for Producing Hydrogen Gas BACKGROUND OF THE INVENTION

The present invention relates to a micro component hydrocarbon steam reformer system for producing hydrogen gas and a reaction cycle useful in the system. Particularly, the system relates to micro component apparatus and cycles useful in powering fuel cells adapted for motor vehicle use and other discrete systems having incremental and/or scalable energy requirements.

io Hydrogen fuel cells are non-polluting, highly efficient power sources.
<www.eren.doe.gov/RE/hydrogen_fuel_cells.html>. See, for example, FUEL
CELLS GREEN POWER, Los Alamos National Laboratory, U.S. Department of Energy, 1999.

The use of fuel cells (despite their desirable characteristics) in motor vehicles, transportation, mobile and "small scale" applications (varying from powering a laptop computer to providing power for an entire home), where a discrete source of hydrogen is required, is hindered because a convenient, safe and/or mobile source of hydrogen having a size appropriate for the discrete use is not available.

It is an object of the invention to provide a hydrocarbon steam reformer system that produces a hydrogen-enriched gas, such as used to feed an electric power producing fuel cell. It is a further object to provide such a system in a configuration and using a cycle that is convenient, safe, and adaptable for small scale use and is incrementally scalable to adjust to predetermined power requirements.

Prior art convention in fuel cell technology, generally in automotive applications, employs an auto-thermal reforming system that, through a sequence of known chemical reactions, converts hydrocarbons, water and air into hydrogen-enriched gas that feeds a fuel cell. Steam reformer systems are known; but the art is skeptical of the adaptability of steam reformer systems for motor vehicle use. See "Fuel Cell Technology," Automotive Engineer, September 2000, pages 78 et seq. In contrast, the system of the invention io enables the use of a steam reforming process for automotive and other predetermined power requirement applications, achieves improved operating efficiencies, and is adapted to scalable operation and expansion in discrete modular assemblies. The invention offers the advantages of small size and is volumetricaliy scalable with respect to flow rates as determined by power requirements for a specific situation.

SUMMARY OF THE INVENTION

In the preferred embodiment of the invention, an energy balanced reaction cycle converts gasoline, a liquid mixture of hydrocarbon compositions (CXHy) having properties approximated by an iso-octane (C8H18) model, and water (H20), into a hydrogen (H2) enriched syn-gas fuel for powering a fuel cell.
An external heat source initiates the cycle and the steam reformer cycle of the system is fed and partly fueled by a source of hydrocarbons. The greater efficiency of the system and the increased concentration of H2 in the syn-gas produced by the invention contrasts with auto-thermal systems. Auto-thermal systems convert gasoline, water and air into a hydrogen (H2) enriched syn-gas.
The addition of air lowers system efficiency and generally produces an H2 concentration with a mole fraction in the range of about .3 to about .4 with a high concentration of nitrogen, a mole fraction of about .45, requiring a high flow rate, less contact time in reaction chambers and larger reactor size.

The steam reforming cycle and system of the invention produces H2 concentrations in the mole fraction range of about .65 to about .75. Using a steam reformer, the cycle feeds a stream of gasoline (or other suitable hydrocarbon) through a series of catalytic reactors and heat exchangers to io produce a hydrogen (H2) enriched syn-gas to power a fuel cell in the system cycle. External energy to drive the steam reforming process and to effect the vaporization of liquids introduced into the system is produced by fuel cell off gas and gasoline mixed with ambient air. The external energy generates heat to drive the steam reforming and vaporization processes in novel micro component reactor and heat exchanger modules and devices.

Hydrogen is stored in a minor quantity by a suitable method, and introduced from storage to a starter module that includes a vaporizer which initiates the cycle. The cycle thereafter operates from a combination of the fuel cell off gas and gasoline, producing syn-gas useful for powering a fuel cell.
The system does not require a continuous injection of hydrogen from an external source.

The invention is described more fully in the following description of the preferred embodiment considered in view of the drawings in which:

BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a schematic diagram of the system and cycle.

Figure 1A, Figure 1 B, Figure 1 C, and Figure 1 D show characteristics of the vaporizer, heat exchanger, steam reformer and water/gas shift component devices used in a system.

Figure 2 depicts representative process temperatures in the cycle in the designated modules correlated with like modules identified in Figure 1.

Figure 3A represents in an enlarged perspective detail, a view of channels that direct laminar fluid flow in micro component assembly devices used in the system.

Figure 3B represents a section of wavyplate separator useful in a laminar flow micro component module having different catalyst compositions on opposite sides to promote the different reactions occurring in the fluid flows on either side of the separator.

Figure 3C is a detail of a perspective and cross sectional view of a section of a laminar flow micro component module showing channels on opposite sides of a separator plate for directing fluid flow.

Figure 4 is a representation of an embodiment of the invention utilizing a start module, also showing fluid flow and principal components in the system used with a hydrogen fuel cell.

2o DETAILED DESCRIPTION OF THE INVENTION AND THE PREFERRED
EMBODIMENT

Generally described, the system and cycle of the invention is a steam reformer system for producing hydrogen enriched gas from liquid or vaporized hydrocarbons. In an embodiment, gasoline is steam reformed in a cycle to produce H21 preferably to power a fuel cell. In the cycle, the off gas of the fuel cell is utilized as a source of heat energy to power the cycle. A vaporized hydrocarbon is mixed with fuel cell off gas having a hydrogen component and combusted to heat the steam reformer. Vaporized hydrocarbons and water vapor are introduced into the steam reformer to produce a syn-gas primarily comprising H2, C02, CO, H20, and CH4. The gas is cooled. CO is removed. The resulting principally hydrogen gas is introduced into the hydrogen fuel cell.
Water and gasoline are vaporized then mixed; the mixture is processed and ultimately directed to a high temperature steam reformer and then to a water gas shift reactor where hydrogen gas is produced in known reactions approximated by the equations: C$H18 + 12H20 =~ 4C0 + 4CO2 + 21 H2 and CO
+ H2O --= C02 + H2.

The resulting H2 rich syn-gas is then preferentially oxidized in a reactor prior to introduction into the fuel cell. The fuel cell will utilize about 60%
to about 90% of the H2 in the syn-gas mixture. The remaining unutilized H2 exits the fuel cell and is mixed with hydrocarbons (gasoline) to supply energy to drive the heat exchange, vaporization, steam reformer and water gas shift processors and reactors in the system.
The cycle is started using hydrogen from the fuel cell off gas that is stored in a suitable vessel interconnected with the system. The cycle operates independently after start-up. A suitable starting device is described in our United States Patent 6,716,400 "Ignition System For a Fuel Cell Hydrogen Generator"
issued on April 6, 2004. The starting device is a module that includes a vaporizer and a combustor initiated by the stored fuel cell off gas hydrogen. Once initiated and operating, the heat energy source for the system comprises vaporized hydrocarbons and fuel cell off gas that provide the energy to drive the system.
The off gas/hydrocarbon mixture is catalytically combusted in the system in micro component vaporizer and steam reformer devices that are serially interconnected in conformance with the processing sequences described herein.
After the steam reformer processing, H2 is produced in a gas mixture which is then treated in a water gas shift reactor and preferentially oxidized before the gas is introduced into the fuel cell to remove CO that may otherwise poison the fuel cell.

An example of the system and cycle illustrated in Figure 1 is described below:

EXAMPLE I

With reference to Figure 1, a fuel processor for processing hydrocarbon fuel to produce hydrogen includes first and second fuel vaporizers 14 and 22, water vaporizer 18, mixer 26 for mixing vaporized fuel and fuel cell off gas, first heat exchanger 30, steam reformer 34, second heat exchanger 38, first water gas shift reactor 42, third heat exchanger 46, second water gas shift reactor 50, fourth heat exchanger 54, preferential oxidation reactor 60, storage tank 64 for storing fuel cell off gas, and fuel cell stack 68.

In the fuel processor, a hydrocarbon fuel, preferably a liquid fuel such as gasoline, is vaporized by the first fuel vaporizer 14. (In an embodiment, energy for vaporizer 14 may be provided by the combustion of fuel cell off gas maintained in a buffer or other storage.) The vaporized fuel is mixed with stored fuel cell off gas, or hydrogen, from storage tank 64 in mixer 26 until the fuel processor is heated and running, at which point the vaporized liquid hydrocarbon fuel is mixed in mixer 26 with fuel cell off gas from the fuel cell stack 68.
The mixture of fuel cell off gas and vaporized fuel from the mixer 26 is introduced into and primarily catalytically burned in the water vaporizer 18 to vaporize water, raising the temperature of the water from ambient temperature (approximately 25 C) to approximately 350 C. The off gas/hydrocarbon mixture may also be introduced for catalytic burning in the second fuel vaporizer 22 and steam reformer 34. Temperatures provided throughout relate to specific experimental models and are variable dependent on component design, system catalyst and lo heat characteristics, overall tolerances, flow rates, and other design and reaction criteria.

In the second fuel vaporizer 22, hydrocarbon fuel for the steam reformer 34 is vaporized, raising the temperature of the feed stream from ambient (approximately 25 C) to approximately 350 C. The vaporized fuel from the second fuel vaporizer 22 and the water vapor from the water vaporizer 18 are mixed and fed to the first heat exchanger 30. The mixture of fuel and water vapor is heated to approximately 700 C and fed to the steam reformer 34. In the steam reformer 34, the fuel and water vapor undergo a catalyst induced reaction to produce syn-gas comprising H2, C02, CO, H20, and CH4. Heat generated in the steam reformer 34 is directed back to heat exchanger 30 and combustor 22.
Where heat transfer is from a higher to lower temperature, a recouperative heat exchanger module (i.e., without a catalyst) may be utilized.

The syn-gas leaves the steam reformer and passes through a second heat exchanger 38, where water is added to the syn-gas to cool the syn-gas to approximately 450 C. The syn-gas then passes through a first water gas shift reactor 42 to reduce the proportion of CO component gas from the syn-gas mixture. The syn-gas then passes through third heat exchanger 46, where water is added and the syn-gas cools to approximately 250 C. The syn-gas then passes through second water gas shift reactor 50 to further reduce the CO
component from the syn-gas. In the water gas shift reactors, the catalyst induced reaction is CO + H2O <-->H2 + CO2. After exiting the second water gas shift reactor 50, the gas passes through a fourth heat exchanger 54, which reduces the syn-gas temperature to approximately 100 C. Finally, the syn-gas is io passed through the preferential oxidation reactor 60 and to the fuel cell bank 68.
The off-gas from the fuel cell is then routed back to the mixer 26 and/or storage/buffer tank 64. Water produced in the fuel cell 68 may be cycled in the system, for example, to add water to the syn-gas at the second and third heat exchangers 38 and 46, or stored as a feed stock.

Zeolite crackers known in the art may be placed after the first and/or second fuel vaporizers 14 and 22 to break down a hydrocarbon fuel such as gasoline, into lighter hydrocarbons that may catalytically burn easier in heating the water vaporizer 18 and steam reformer 34.

Figure 1A, Figure 113, Figure IC and Figure I D show in cross-section characteristics of the system component vaporizers 14, 18 and 22, heat exchangers 30, 38, 46 and 54, steam reformer 34, and water gas shift reactors 42 and 50 used in the system. Using a vaporizer 200 as an example in Figure 1A, separate laminar fluid flows are directed through adjacent volumes 201 and 202 in a micro component structure with a separator 203 forming adjacent channels for directing laminar fluid flow. In the vaporizer, the liquid water or hydrocarbon composition passes through one volume 201 of the component assembly to be vaporized as the result of heat exchanged by conduction with the fluid flow of heated gas in the adjacent volume 202 of the component assembly.

Heat exchangers for the system are similarly structured micro component devices. Heat exchanger 300 shown in Figure 1 B provides separate laminar fluid flow channels directed through adjacent volumes 301 and 302 on opposite sides of a separator 303 in the device in which heat energy between the two adjacent channels may be exchanged primarily by conduction or diffusion, depending on io whether the respective fluids are in a vaporized liquid or gas state.

Likewise steam reformer 34 shown as 400 in Figure 1 C, provides separate laminar fluid flow channels directed through adjacent volumes, optimally, a catalytic reaction chamber 401, and a fluid flow heat source 402 on opposite sides of a separator 403 in the device in which heat is exchanged primarily by diffusion and conduction between gas flows on opposite sides of the separator.
The water/gas shift reactors 42 and 50 are similarly structured devices with separated channels for directing fluid flow in the channels defined by the separators on their opposite sides as shown in the reactor 500 of Figure 1 D
having separated channels 501 and 502 formed by channel separator 503.

In the modules in which a reaction occurs, the side of the separator component on which a reaction occurs is optimally coated with an appropriate catalyst to induce the appropriate process reaction within the module on that side of the separator.
Figure 3A illustrates in enlarged detail a section of a wavyplate separator in a micro component assembly used in the system, and the relationship of the separator to fluid flows on its opposite sides. The separate fluid flows on the opposite sides of the wavyplate may be in the same or in opposite directions.
In Figure 3A, a shaped or folded wavyplate 320 has two opposite sides 321 and 322 (322 is shown coated with a catalyst material 324), respectively exposed to laminar fluid flows 331 and 332 in a heat exchanger assembly. Such types of devices used in the system are described in United States Patent 6,946,113 issued September 20, 2005, entitled "Method for Processing Fluid Flows in a Micro Component Reformer System" owned by the assignees of the present application.
In one embodiment as a steam reformer chamber shown in Figure 3B, the one side of the wavyplate 321 is formed with a coating of a metal oxide catalyst material 321A to promote the steam reforming reaction in fluid flow on that side of the separator plate. Maintenance of the steam reforming reaction requires that heat be input into the exchanger. The sustained 700 C heat for the steam reforming reaction is provided by a further catalytically induced exothermic reaction, in the fluid flow on the opposite side of the separator, of a mixture of combustible materials, such as fuel cell off gas containing hydrogen, and/or gasoline, and air on the opposite side of the separator plate which is coated with a catalyst 321 B. In an example, center points of the sections (top to top) of the wavyplate are approximately 3.0 millimeters apart. The preferred steam reformer is a micro component assembly having a high heat flux in which separate sections of a heat exchanger are divided by a thin plate having an oxidation catalyst on one side (exothermic, to provide heat) and a steam reforming catalyst (endothermic) on the other, in which heat transfer occurs by conduction. Fluid flow on opposite sides of the separator may be in the same (co-flow) or opposite (counter-flow) directions.
In the various modules used in the system, the separator should be as thin and rigid as possible, in the order of magnitude of approximately 100 microns to approximately 1000 microns as a maxitnum. Inconel is a useful material. Design parameters depend on accommodating thinness with separator rigidity and heat transfer characteristics, i.e., nT /Thickness. In the operation of the cycle, heat transfer between fluids is optimally balanced depending on the flow rate of the fluid passing in the steam reformer, the rate of steam reforming, the catalysts on both sides, the capability of the oxidation catalyst and the flow rate on the oxidation side. Heat utilization an/or catalyst characteristics on the steam reforming side are design factors.
Figure 3C shows a section of a micro component module 320 with a wavypiate separator 321 forming channels for laminar flow 331 and 332 on both sides of a separator in an enclosure having lower and upper sides 335A and 335B. For clarity, the right and left sides and inlet and outlet orifices for flow in the channels of the module are not shown. As noted above, micro component assemblies useful to be adapted to vaporizer, heat exchanger, steam reformer and water/gas shift devices for the system are described in U.S. Patent 6,946,113 owned by the assignee of the present application.
With reference to the various system modules shown in Figure 1, the following Table I relates the modules to reference numerals in the drawings, functions and reactions accomplished, and the approximate preferred (design optimum) temperatures related to the fluid processing accomplished therein:

TABLE I
Module Reference Function Reaction Temperature C
No.

14 Vaporizer Hydrocarbon (gasoline) 25 in / 350 out fuel is vaporized.
18 Vaporizer Liquid water In: 25 is vaporized. Out: 500 +/- 200 22 Vaporizer Hydrocarbon (gasoline) In: 25 fuel is vaporized. Out: 500 +/- 200 30 Heat Exchanger The temperature of the In: 500 +/- 200 hydrocarbon/water Out: 800 +/- 200 vapor mixture is increased.
34 Steam Reformer Catalyst induced reaction to produce syn- 800 +/- 200 gas: H2, CO2, CO, H2O, and CH4.
38 Heat Exchanger In: 800 +/- 200 Out: 350 42 Water/Gas Shift CO is removed from the Reactor syn-gas. 350 CO + H2O F-->H2 + CO2 46 Heat Exchanger In: 350 +/-Out: 200 +/-50 Water/Gas Shift CO in syn-gas is 200 Reactor optimally reduced to 10ppm.
CO + H2O <--*H2 +
CO2.
54 Heat Exchanger 100 +/-60 Preferential 100 +/-Oxidizer Although current optimal temperatures and ranges determined by testing and simulation are provided, optimal temperatures and ranges depend on interrelationships among components, laminar flow characteristics, and system design parameters. Modules 38 and 46 are principally water vaporizers where heat is provided on one side of the module to vaporize water (vapor) flowing on the other side, and depending on design factors otherwise, may not require an exothermic catalyst on the side opposite the water/vapor flow.

In a similar manner, Table II (considered in conjunction with Figure 1 and lo Figure 2) relates the micro component modules to the properties of the opposite sides of the separators in the devices with regard to the functions and/or reactions in the fluid flow passing on opposite sides and the catalyst properties of the respective separator sides. Useful catalysts identified with respect to the example include platinum, palladium, cerium oxide, aluminum hydroxide and cuprous oxide; other suitable catalysts may be substituted for the functions specified. In steady state simulations, catalyst composition for the steam reformer and water gas shift reactors are not factors.

TABLE II

Module Separator Properties Reference No.
and Function Flow Side One Flow Side Two 14 Hydrocarbon (gasoline) fuel 25 in / 350 out Vaporizer is vaporized. Catalyst: : Pd, Pt Catalyst: None Reference No. 14 (out) Reference No. 14 (in) 18 Liquid water 25 in / 350 out Vaporizer is vaporized. Combustor for HC and H2 Catalyst: None Catalyst: : Pd, Pt Reference No. 18 (in) Reference No. 18 (out) 22 Hydrocarbon (gasoline) fuel 25 in / 350 out Vaporizer is vaporized. Combustor for HC and H2 Catalyst: None Catalyst: : Pd, Pt Reference No. 22 (out) Reference No. 22 (in) 30 The temperature of the 350 in / 700' out Heat hydrocarbon/water vapor Exchanger mixture is increased. Catalyst: : Pd, Pt Catalyst: None Reference No. 30 (out) Reference No. 30 (in) 34 Oxidation side: Steam Reformer side:
Steam Catalyst induced reaction 700 Reformer To produce syn-gas: H2, Combustor for HC and H2 C02, CO, H20, and CH4.
Catalyst: Pd, Pt Catalyst: Pd, Pt/CeO/AIzO3 Reference No. 34 (in) Reference No. 34 (out) 38 700 in / 450 out Heat Exchanger Catalyst: Pt/Pd Catalyst: None Reference No. 38 (in) Reference No. 38 (out) 42 CO is removed from the 450 Water/Gas syn-gas. Heat exchange.
Shift CO + H20 --H2 + CO2 Reactor Catalyst: Pt, CeO Catalyst: None Reference No. 42 (in) Reference No. 42 (out) Heat 350 in / 250 out Exchanger Catalyst: Pt, Pd Catalyst: None Reference No. 46 (in) Reference No. 46 (out) 50 CO in syn-gas is optimally 250 Water/Gas reduced to 10ppm. Heat Exchange.
Shift Reactor CO + H20 --H2 + CO2.
Catalyst: CuO Catalyst: None Reference No. 50 (in) Reference No. 50 (out) Heat Catalyst: None Catalyst: None Exchanger Reference No. 54 (in) Reference No. 54 (out) Preferential Catalyst: Pt, Pd 100 Oxidizer Reference No. 60 (in) Catalyst: None Reference No. 60 (out) EXAMPLE II

A second example is shown in Figure 4. In operation, the process is self-sustaining from fuel sources of hydrocarbons and water. A balanced isothermal reactor is provided that converts gasoline and water into hydrogen enriched gas 5 that powers the fuel cell bank. The gasoline vapor supplies all combustors used for heating in the system; gasoline is both a fuel (as a source of heat for the combustors) and the raw material used in the production of hydrogen enriched gas. In the combustors, heat is generated from gasoline by means of a catalytic combustion reaction induced by a catalyst. Heat is transferred to the fluid on the opposite side of the separator as explained above. Stored hydrogen is used only when the system is started to initiate combustion in the first vaporizer.

Figure 4 shows the system in conjunction with a starting device and a fuel tank and also illustrates the relationships of the micro component modules and their sections as involved in fluid flow in the system. In Figure 4, an external fuel bank includes separate storage tanks for the storage of predetermined quantities io of water (H20), gasoline (or other hydrocarbon fuel) and fuel cell off gas (or hydrogen (H2)) used in the system. A start module includes sections respectively indicated as combustor, vaporizer and combustor assembled in a common module. As noted, the start-up device is described in our application to be filed. In starting the processor, hydrogen mixed with air is introduced into combustor and generates sufficient heat to vaporize gasoline and produce hydrocarbon vapor that is mixed with hydrogen to supply heat energy to combustor. Once fluid flow and reactions balance in the system, the flow of stored hydrogen is terminated and vaporizer and combustor in the system perform in the continuous reaction cycle equivalently to vaporizer 14 shown in 2o Figure 1.

Table III describes properties of the combustor, vaporizer and combustor sections of the starting device shown in Figure 4. The starting device may be configured as a "sandwich" of units having the characteristics of the assembly shown in Figure 3C".
TABLE III

Module Module Section Properties Function Combustor Vaporizer Combustor Combustor/ Hydrogen is mixed Gasoline is Vaporized Vaporizer/ with air and burned. vaporized. gasoline is mixed Catalyst: Pd Catalyst: None with fuel cell off Combustor gas, combusted and heat energy is directed to the vaporizer section.
Catalyst: Pt/Pd Gasoline is the preferred fuel in the invention, because of its widespread production and distribution network, its general availability and its utility as a feed stock in the steam reforming process. In virtual modeling of the system, iso-octane (C8H18) was the preferred embodiment hydrocarbon for providing heat energy (mixed with fuel cell off gas) and for providing the feed stock component for the steam reforming in the model base. Gasoline is a mixture comprising approximately 50 or more hydrocarbons, CxHy; iso-octane C8Hy is a surrogate used as a model in virtual process simulations.

The system is scalable to meet varying power requirements in which incremental design units are determined by the number of channels in the separate HEX (heat exchange, catalyst, reactor and processor) units as well as the number of HEX units. Channels in the units having a predetermined point to point separation are optimally designed to have a maximum depth allowing fluid flow to pass over a maximized surface area. For example, the length of a channel determines the residence time of a fluid increment and is in turn dependent on pressure change in the channel. In an example of a channel unit with a nominal channel gap of 250 microns +/- 50 microns (allowing for the thickness of a catalyst coating) the channel separation to depth aspect ratio may be in the range from about 1:10 or 1:25 to 1:100, determined by design considerations, to maximize surface area and reaction efficiency as design parameters.

The system is an energy conversion unit with overall power production ranges extending from a few watts to megawatts scalable units of the systems are useful in robotics, laptop computers, micro electronic devices, automobile io engines, hydrogen re-fueling stations and other mobile or fixed location applications where a discrete, as opposed to distributed, source of hydrogen is required by preference or necessity. The system is assembled from micro component devices that are modular and scalable through the use of small "units", based on laminar channel capacity, that may be assembled incrementally to provide a predetermined source of maximum power. For example, four 25kw units may be incrementally ganged to provide 100kw and operated to provide a continuous 0 - 100kw range and/or configured for optimum power needs such as a 50 - 75kw range.

Fluid flows through the channels as a result of pressure differential is in the order of a differential pressure drop of less than 100 psi; laminar flow through the channels provides a low pressure drop in the system. Water, in the form of condensate from system exhaust, is introduced through a pump, as is the gasoline or hydrocarbon component introduced under pressure. Reaction balance in the system is achieved by variably adjusting pump and compressor pressures to maintain fluid flow such that reactions are balanced.

In addition to, or in combination with gasoline, methanol and ethanol may be used in the system. Methane is a gas and would not need to be vaporized.
As noted, other hydrocarbon fuel sources such as methanol, ethanol, methane, ethane, propane, butane and other hydrocarbon fuels and mixtures thereof may be utilized as combustion sources or hydrogen gas precursors in cycles of the system adapted from the preferred embodiment in accordance with suitable stoiciometric variations that result in a balanced reaction cycle having the lo characteristics described herein. Certain of these hydrocarbons are stored as liquids, but may be introduced to the system as gases, in this instance, eliminating a need in the system for vaporizer components at cycle beginning stages.

Having described the invention in detail, those skilled in the art will appreciate that, given the present disclosure; modifications may be made to the invention without departing from the spirit of the inventive concept herein described. Rather, it is intended that the scope of the invention be determined by the appended claims.

Claims (14)

CLAIMS:
1. In a fuel cell powered apparatus, a system for producing a syn-gas to provide a fuel for the fuel cell comprising:

a mixer for producing a feed stock of vaporized hydrocarbons and water vapor, a steam reformer having (a) an inlet interconnected with the mixer into which the feed stock is directed and (b) an outlet for the syn-gas produced therein, a combustor operatively disposed in contact with the steam reformer to heat the steam reformer, a fuel cell producing an off gas, the fuel cell having an outlet for the off gas interconnected with the combustor for directing the flow of off gas from the fuel cell to the combustor, the steam reformer and combustor being separated within a micro component enclosure formed from an upper plate and a lower plate bounded on the perimeter by sealed sides in which a wavyplate divides the enclosure into multiple side by side parallel micro channels for fluid flow longitudinally extending in the interior of the enclosure, the channels extending in height in the interior of the enclosure from the upper plate to the lower plate, the channels being separated from each other by the wavyplate and comprising a first set of micro channels on one side of the wavyplate and a second set of micro channels on the opposite side of the wavyplate and forming a plurality of alternating longitudinally extending and parallel micro channels for steam reform fluid flow and micro channels for combustor flow on the opposite facing sides of said wavyplate; micro channels for steam reform flow having sides coated with a catalytically active steam reforming material and effecting laminar fluid flow of feed stock from said mixer, and said combustor micro channels effecting laminar fluid flow of the off gas from said fuel cell, whereby the laminar fluid flow of each of the steam reform flow and the feed stock flow is maintained in the micro channels in a stoichiometric relationship.
2. The apparatus of claim 1 in which the wavyplate is a folded shaped separator maintained in a middle section of the enclosure, the folds in the separator extending in the interior of the enclosure from a valley at the lower plate to a peak at the upper plate, and wherein the steam reform flow micro channels are on a first side of said wavyplate and are coated with an endothermic steam reforming catalyst and the combustor flow micro channels are on a second side of said wavyplate opposite the first side and are coated with an exothermic oxidation catalyst.
3. The apparatus of claim 2 wherein the enclosure is a module includes an upper plate and a lower plate surrounded by an enclosed perimeter defining a volume for fluid flow through the module and the separator comprises a folded divider having alternating crests and troughs forming channels on opposite sides thereof, the divider being disposed between the upper plate and the lower plate wherein the point to point separations of the crests and troughs disposed between the upper plate and the lower plate define fluid flow channels on the opposite sides of the separator.
4. The apparatus of claim 1 including at least one heat exchange module in addition to the steam reformer/combustor module interconnected in line with the combustor and the steam reformer in which a first fluid flow is introduced into a plurality of fluid flow channels on a first side of the additional heat exchange module and a second fluid flow is introduced into a plurality of channels formed on a second side of the additional heat exchange module opposite the channels of the first side, the additional module comprising a micro component assembly formed from an upper plate and a lower plate bounded on the perimeter by sealed sides in which a wavyplate divides the enclosure into multiple side by side parallel micro channels for fluid flow longitudinally extending in the interior of the enclosure in which the channels extend in height in the interior of the enclosure from the upper plate to the lower plate, and the channels are separated from each other by the wavyplate to form a first set of micro channels on one side of the wavyplate and a second set of micro channels on the opposite side of the wavyplate.
5. The apparatus of claim 4 including a zeolite cracker disposed in the fluid flow path behind the vaporizer and in advance of the steam reformer.
6. Apparatus of claim 1 in which the micro channels are adapted to produce a laminar fluid flow therein and have a width to depth aspect ratio of from about 1:10 to about 1:100.
7. Apparatus of claim 1 or claim 4 configured as a steam reforming system for the production of a syn-gas to power the fuel cell including: a) a start module, a pre heater module and a vaporizer module in advance of the steam reformer and b) a water gas shift reactor module and a heat exchanger module for cooling the fluid flow of gas from the steam reformer behind the steam reformer in an in-line serial interconnection wherein a closed loop fluid flow path from the fuel cell off gas outlet to the combustor is defined by a segment of the fluid flow path including a plurality of serially interconnected separate modules wherein micro channels provided in more than one of the start module, pre heater module, the vaporizer module, the water gas shift reactor module, and the heat exchanger module are formed by a folded wavyplate shaped separator maintained in a middle section of the module, the folds in the wavyplate extending from a valley in contact with the interior surface of the lower plate of the enclosure that forms the module to a peak in contact with the interior surface of the upper plate of the enclosure that forms the module and the micro channels in the modules have a width to depth aspect ratio of from about 1:10 to about 1:100.
8. Apparatus- of claim 1 wherein the sidewalls of the micro channels for steam reform flow in the steam reformer and combustor micro component enclosure include a catalyst thereon selected from the group of one or more of platinum, palladium, cerium oxide, aluminum hydroxide and cuprous oxide.
9. Apparatus of claim 7 wherein the sidewalls of the micro channels for steam reform flow in the steam reformer and combustor micro component enclosure include a catalyst thereon selected from the group of one or more of platinum, palladium, cerium oxide, aluminum hydroxide and cuprous oxide.
10. Apparatus of claim 1 or claim 7 including a hydrocarbon fuel source interconnected with the mixer wherein the hydrocarbon is vaporized in the mixer.
11. Apparatus of claim 1 or claim 7 including a preferential oxidation reactor an a fluid flow path behind the steam reformer.
12. A hydrocarbon fueled power source including, in a serial in line interconnection, a mixer interconnected with a hydrocarbon source and a water source and a vaporizer for producing a feed stock of vaporized hydrocarbons and water vapor, a steam reformer interconnected with the vaporizer into which the feed stock is directed, combustor operatively disposed with respect to the steam reformer for generating heat energy from fuel cell off gas to heat the steam reformer, a fuel cell having an off gas outlet interconnected with the combustor for directing the flow of off gas from the fuel cell to the combustor, and an exit from the steam reformer for directing the syn-gas produced therein to the fuel cell, in which the vaporizer, combustor and steam reformer each comprise a micro component module having an upper plate and a lower plate surrounded by a perimeter enclosure defining a volume for fluid flow through the module and a folded wavyplate shaped separator in the midsection of the module forms separated side by side parallel micro channels having a width to depth aspect ratio of from about 1:10 to about 1:100 maintained in the module, the wavyplate including folds extending from a valley at the lower plate to a peak at the upper plate, and the wavyplate dividing the enclosure into a first set of longitudinally extending micro channels on a first side and a second set of longitudinally extending micro channels on an opposite side of said wavyplate, the interior sidewalls of at least one set of micro channels having a reaction catalyst thereon, whereby the micro channels of said first set alternates with the micro channels of said second set such that laminar fluid flow through said first and second sets is maintained and the laminar fluid flow effects a stoichiometric energy exchange between separated fluids respectively flowing through said first and second sets of micro channels.
13. The apparatus of claim 12 wherein the steam reformer and combustor are enclosed within a same module and fluid flow from and to the steam reformer is directed through a first set of micro channels having a steam reforming catalyst on the sidewalls thereof and fluid flow from and to the combustor is directed through a second set of micro channels having an oxidation catalyst on the sidewalls thereof, the micro channels respectively being on opposite sides of the separator within the module and wherein off gas from the fuel cell is introduced into the second set of micro channels which form the combustor and heat transfer from one of said sets to the other of said sets is effected by conduction through the separator.
14. A power source in accordance with claim 12 or claim 13 wherein fluid flow within the micro channels is laminar and is scalable in increments as determined by the stoichiometric balance of parameters of the fluids subjected to laminar flow within the micro channels.
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